Electrode configurations for surgical instruments

ABSTRACT

An end effector includes a first electrically conductive layer and a second electrically conductive layer comprising an electrically conductive projection extending from the second electrically conductive layer, wherein at least one of the first electrically conductive layer and the electrically conductive projection is movable relative to the other one of the first electrically conductive layer and the electrically conductive projection to capture tissue therebetween.

BACKGROUND

The present disclosure relates to surgical instruments and, in variouscircumstances, to surgical sealing and transecting instruments.

SUMMARY

In one embodiment, a surgical instrument is provided. The surgicalinstrument comprises an end effector. The end effector comprises a firstjaw comprising a first electrically conductive layer and a second jaw,wherein at least one of the first jaw and the second jaw is movablerelative to the other one of the first jaw and the second jaw totransition the end effector between a first configuration and a secondconfiguration. In at least one embodiment, the second jaw comprises asecond electrically conductive layer defining at least one opening andan electrically non-conductive layer, wherein the first electricallyconductive layer and the electrically non-conductive layer areconfigured to be on opposite sides of the second electrically conductivelayer. In at least one embodiment, the second jaw further comprises atleast one electrically conductive member extending from the electricallynon-conductive layer and projecting through the at least one opening tomaintain a predetermined gap between the first electrically conductivelayer and the second electrically conductive layer, wherein the secondelectrically conductive layer is configured to conduct electrical energyto the first electrically conductive layer and the at least oneelectrically conductive member through tissue disposed between the firstjaw and the second jaw in the second configuration to treat the tissue.

In another embodiment, an end effector for a surgical instrument isprovided. The end effector comprises a first electrically conductivelayer and a second electrically conductive layer comprising anelectrically conductive projection extending from the secondelectrically conductive layer, wherein at least one of the firstelectrically conductive layer and the electrically conductive projectionis moveable relative to the other one of the first electricallyconductive layer and the electrically conductive projection to capturetissue therebetween. The end effector further comprises a firstelectrically non-conductive support comprising a first aperture, whereinthe electrically conductive projection extends through the firstaperture. In at least one embodiment, the end effector further comprisesa third electrically conductive layer comprising a second aperture,wherein the electrically conductive projection extends through thesecond aperture, and wherein the first electrically non-conductivesupport is positioned between the second electrically conductive layerand the third electrically conductive layer.

BRIEF DESCRIPTION OF THE DRAWINGS

The features and advantages provided in this disclosure, and the mannerof attaining them, will become more apparent and the disclosure itselfwill be better understood by reference to the following description ofinstances of the disclosure taken in conjunction with the accompanyingdrawings, wherein:

FIG. 1 illustrates a perspective view of a surgical instrumentcomprising a handle assembly and an end effector, according to oneembodiment;

FIG. 2 illustrates a perspective view of the surgical instrument of FIG.1, according to one embodiment;

FIG. 3 illustrates a side elevational view of the handle assembly of thesurgical instrument of FIG. 1, according to one embodiment;

FIG. 4 illustrates a perspective view of an end effector of the surgicalinstrument of FIG. 1, according to one embodiment;

FIG. 4A illustrates a partial cross-sectional view of the end effectorof FIG. 4, wherein tissue is captured between a first jaw and a secondjaw of the end effector, and wherein the end effector includes aplurality of conductive protrusions, according to one embodiment;

FIG. 4B illustrates a partial cross-sectional view of the end effectorof FIG. 4, wherein tissue is captured between a first jaw and a secondjaw of the end effector, and wherein the end effector includes aplurality of protrusions each comprising an electrically conductiveportion extending from an electrically non-conductive portion, accordingto one embodiment;

FIG. 4C illustrates a partial cross-sectional view of the end effectorof FIG. 4, wherein tissue is captured between a first jaw and a secondjaw of the end effector, and wherein the end effector includes aplurality of protrusions each comprising an electrically conductiveportion extending from an electrically non-conductive portion andpartially enclosed in an electrically non-conductive barrier, accordingto one embodiment;

FIG. 5 illustrates a perspective view of a jaw of an end effector of thesurgical instrument of FIG. 1, according to one embodiment;

FIG. 5A illustrates partial cross-sectional view of the end effector ofFIG. 5, wherein tissue is captured between a first jaw and a second jawof the end effector, and wherein the end effector includes a pluralityof protrusions extending from an electrically conductive layer,according to one embodiment;

FIG. 6 illustrates an exploded view of a jaw of the end effector of FIG.4, according to one embodiment;

FIG. 7 illustrates a side elevational view of a jaw of an end effectorof the surgical instrument of FIG. 1, according to one embodiment;

FIG. 7A illustrates a partial cross-sectional view of the jaw of FIG. 7,according to one embodiment;

FIG. 8 illustrates a perspective view of a jaw of an end effector of thesurgical instrument of FIG. 1, according to one embodiment;

FIG. 9 illustrates a partial cross-sectional view of the end effector ofFIG. 8, wherein tissue is captured between a first jaw and a second jawof the end effector, wherein the end effector includes a plurality ofprotrusions extending from an electrically conductive layer, and whereineach protrusion is partially enclosed in an electrically non-conductivebarrier, according to one embodiment; and

FIG. 10 illustrates a perspective view of a protrusion or projection ofthe jaw of an end effector of the surgical instrument of FIG. 1,according to one embodiment.

Corresponding reference characters indicate corresponding partsthroughout the several views. The exemplifications set out hereinillustrate various embodiments of the disclosure, in one form, and suchexemplifications are not to be construed as limiting the scope of thedisclosure in any manner.

DETAILED DESCRIPTION

Certain example embodiments will now be described to provide an overallunderstanding of the principles of the structure, function, manufacture,and use of the devices and methods disclosed herein. One or moreexamples of these embodiments are illustrated in the accompanyingdrawings. Those of ordinary skill in the art will understand that thedevices and methods specifically described herein and illustrated in theaccompanying drawings are non-limiting example embodiments and that thescope of the various embodiments of the present disclosure is definedsolely by the claims. The features illustrated or described inconnection with one example embodiment may be combined with the featuresof other embodiments. Such modifications and variations are intended tobe included within the scope of the present disclosure.

The terms “comprise” (and any form of comprise, such as “comprises” and“comprising”), “have” (and any form of have, such as “has” and“having”), “include” (and any form of include, such as “includes” and“including”) and “contain” (and any form of contain, such as “contains”and “containing”) are open-ended linking verbs. As a result, a surgicalsystem, device, or apparatus that “comprises,” “has,” “includes” or“contains” one or more elements possesses those one or more elements,but is not limited to possessing only those one or more elements.Likewise, an element of a system, device, or apparatus that “comprises,”“has,” “includes” or “contains” one or more features possesses those oneor more features, but is not limited to possessing only those one ormore features.

The terms “proximal” and “distal” are used herein with reference to aclinician manipulating the handle portion of the surgical instrument.The term “proximal” referring to the portion closest to the clinicianand the term “distal” referring to the portion located away from theclinician. It will be further appreciated that, for convenience andclarity, spatial terms such as “vertical”, “horizontal”, “up”, and“down” may be used herein with respect to the drawings. Surgicalinstruments, however, can be used in many orientations and positions,and these terms are not intended to be limiting and/or absolute.

Various example devices and methods are provided for performinglaparoscopic and minimally invasive surgical procedures. The variousmethods and devices disclosed herein can be used in numerous surgicalprocedures and applications including, for example, in connection withopen surgical procedures. As discussed in the present DetailedDescription, the various instruments disclosed herein can be insertedinto a body in any way, such as through a natural orifice, through anincision or puncture hole formed in tissue, etc. The working portions orend effector portions of the instruments can be inserted directly into apatient's body or can be inserted through an access device that has aworking channel through which the end effector and elongated shaft of asurgical instrument can be advanced.

FIG. 1 illustrates a perspective view of a surgical instrument 2comprising a handle assembly 4 and an end effector 10 according to oneembodiment. FIG. 2 illustrates a perspective view of the surgicalinstrument 2 of FIG. 1 according to one embodiment and FIG. 3illustrates a side elevational view of the handle assembly 4 of thesurgical instrument of FIG. 1 according to one embodiment. Turning toFIGS. 1-3, one form of an electrosurgical instrument 2 is depicted. Theelectrosurgical instrument 2 comprises a handle assembly 4, a shaftassembly 12 coupled to a distal end of the handle assembly 4, and an endeffector 10 coupled to the distal end of the shaft assembly 12. Thehandle assembly 4 is configured as a pistol grip and comprises left andright handle housing shrouds 6 a, 6 b, a closure trigger 8, apistol-grip handle 14, a firing trigger 16, an energy button 18, and arotatable shaft knob 20. An electrical cable may enter the handleassembly 4 at a proximal end 15.

In some circumstances, the end effector 10 can be coupled to the distalend of the shaft assembly 12. The end effector 10 may include a firstjaw 22 a and a second jaw 22 b. The first jaw 22 a can be pivotablycoupled to the second jaw 22 b. The first jaw 22 a is moveable withrespect to the second jaw 22 b to grasp tissue therebetween. In somecircumstances, the second jaw 22 b is fixed. In other circumstances, thefirst jaw 22 a and the second jaw 22 b are pivotably movable withrespect to each other. The end effector 10 may include one or moreelectrodes such as, for example, electrodes 92, 94. The electrodes 92,94 can be configured to pass energy through tissue positioned betweenthe electrodes 92, 94. Energy delivered by the electrodes 92, 94 maycomprise, for example, radiofrequency (RF) energy, sub-therapeutic RFenergy, therapeutic RF energy, ultrasonic energy, and/or other suitableforms of energy. In some circumstances, a cutting member (not shown) isreceivable within a longitudinal slot 40 (FIG. 4) defined by the firstjaw 22 a and/or the second jaw 22 b. The cutting member can beconfigured to cut tissue grasped between the first jaw 22 a and thesecond jaw 22 b. In some circumstances, the cutting member may includean electrode for delivering energy, such as, for example, RF and/orultrasonic energy.

In certain instances, an energy button 18 is configured to deliverenergy to the at least one electrode 92 from a power source. In certaininstances, when the energy button 18 is depressed, a circuit iscompleted allowing delivery of energy to the electrode 92. In someembodiments, the power source is a generator. In certain instances, thegenerator is external to the surgical instrument 2 which is separablycoupled to the generator. In other instances, the generator isintegrated with the surgical instrument 2. In certain instances, thepower source may be suitable for therapeutic tissue treatment, tissuecauterization/sealing, as well as sub-therapeutic treatment andmeasurement.

In certain instances, the surgical instrument 2 may include a closuredrive assembly which may comprise an outer sheath 23, for example. Incertain instances, the closure trigger 8 can be operatively coupled toat least one of the first and second jaws 22 a, 22 b through the closuredrive assembly such that actuation of the closure trigger 8 in a closurestroke may transition the first and second jaws 22 a, 22 b between aplurality of configurations including an open configuration and anapproximated configuration, for example. In certain instances, thesurgical instrument 2 may include a firing drive assembly. In certaininstances, the firing trigger 16 may be operatively coupled to thecutting member of the end effector 10 through the firing drive assemblysuch that actuation of the firing trigger 16 in a firing stroke maycause the cutting member to be advanced relative to the end effector 10to cut tissue captured between the first and second jaws 22 a, 22 b, forexample.

When electrical current is supplied to an electrode such as, forexample, the electrodes 92, 94, the electrical current can pass throughthe tissue positioned against and/or surrounding the electrode, forexample. In various circumstances, the current flowing through theelectrode can generate heat within the electrode and the surroundingtissue. In certain circumstances, the heat can denature proteins withinthe tissue and, in co-operation with clamping pressure provided by thefirst and second jaws 22 a, 22 b of the end effector 10, the denaturedproteins can form a seal within the tissue, for example.

FIG. 2 illustrates a side perspective view of the electrosurgicalinstrument 2 illustrated in FIG. 1. FIG. 2 illustrates the right handlehousing 6 b. The energy button 18 extends through the handle assembly 4and is accessible on both sides of the handle assembly 4. The closuretrigger 8, the firing trigger 16, and the energy button 18 may comprisean ergonomic design. In some circumstances, the handle assembly 4 isthinner near the energy button 18 to allow ease of access to the energybutton 18 by a clinician. In some circumstances, the energy button 18 isdisposed on either the left handle housing shroud 6 a or the righthandle housing shroud 6 b. FIG. 3 illustrates a side view of theelectrosurgical instrument 2 and the right handle housing shroud 6 b.Various electrosurgical instruments suitable for use with the presentdisclosure are described in U.S. patent application Ser. Nos. 14/075,839and 14/075,863.

FIG. 4 illustrates a perspective view of the end effector 10 of thesurgical instrument 2 of FIG. 1, according to one embodiment. FIG. 4Aillustrates a partial cross-sectional view of the end effector 10 ofFIG. 4, wherein tissue is captured between the first jaw 22 a and thesecond jaw 22 b of the end effector 10, according to one embodiment.FIG. 4B illustrates a partial cross-sectional view of the end effector10 of FIG. 4, wherein tissue is captured between the first jaw 22 a andthe second jaw 22 b of the end effector 10, according to one embodiment.FIG. 6 illustrates an exploded view of the second jaw 22 b of the endeffector 10 of FIG. 4, according to one embodiment. Referring now toFIGS. 4-4C and 6, the second jaw 22 b may include an electricallyconductive layer 42 and an electrically non-conductive layer or support46. One or more protrusions or projections 50 may extend from thenon-conductive layer 46 through the electrically conductive layer 42. Incertain instances, as illustrated in FIG. 6, the electrically conductivelayer 42 may include one or more openings or apertures 44. In certaininstances, one or more of the protrusions 50 may extend from thenon-conductive layer 46 and pass through an opening or aperture 44 ofthe electrically conductive layer 42.

In certain instances, one or more of the protrusions 50 may becomprised, or at least partially comprised, of an electricallyconductive material. As illustrated in FIG. 4B, a protrusion orprojection 50 may include an electrically non-conductive portion 45 andan electrically conductive portion 50 a that extends from thenon-conductive portion 45. The non-conductive portion 45 may extend fromthe non-conductive layer 46. The electrically conductive portion 50 amay extend from the non-conductive portion 45 in a direction away fromthe non-conductive layer 46, as illustrated in FIG. 4B. Thenon-conductive layer 46 and/or the non-conductive portion 45 may becomprised of an electrically non-conductive, or insulative, material,such as plastic and/or ceramic, for example.

In certain instances, as illustrated in FIG. 4B, the electricallyconductive portion 50 a extends through an opening or aperture 44 of theelectrically conductive layer 42. In such instances, the electricallyconductive portion 50 a may be employed to grip tissue in contacttherewith. In at least one example, the electrically conductive portion50 a may comprise a textured or patterned outer surface to improve itsability to grip the tissue.

In certain instances, one or more of the protrusions 50 can be comprisedof an electrically non-conductive material coated, or at least partiallycoated, with an electrically conductive material, for example. Incertain instances, the electrically conductive portion 50 a is comprisedof an electrically conductive surface or coating disposed at a terminalend of the non-conductive portion 45. The electrically conductivesurface may be configured to contact tissue captured between the firstand second jaws 22 a, 22 b. In at least one example, an electricallyconductive surface can be textured or patterned to improve its abilityto grip tissue in contact therewith.

In certain instances, as illustrated in FIG. 4C, the non-conductivelayer 46 may comprise an electrically non-conductive barrier 49. Thenon-conductive barrier 49 may partially enclose or insulate theconductive portion 50 a. In at least one example, the barrier 49isolates the conductive portion 50 a from the conductive layer 42. Anouter surface 51 may remain exposed, as illustrated in FIG. 4C. Thesurface 51 may be configured to contact tissue captured between the jaws22 a, 22 b, for example. In certain instances, as illustrated in FIG.4C, a barrier 49 may extend through an opening or aperture 44 of theconductive layer 42 to surround, or at least partially surround, aprotrusion or projection 50 extending through the opening 44. Thebarrier 49 may prevent, or at least reduce, arcing between theprotrusion 50 and the conductive layer 42.

In certain instances, referring again to FIGS. 4-4C and 6, the electrode92 includes the conductive layer 42. The conductive layer 42 may extendbetween, or at least partially between, the non-conductive layer 46 andtissue captured between the first and second jaws 22 a, 22 b, forexample. In certain instances, electrical current can pass between anelectrically conductive layer 95 of the first jaw 22 a and theconductive layer 42 through the tissue captured between the first andsecond jaws 22 a, 22 b, for example. The conductive layer 95 can bepositioned between an electrically non-conductive layer 97 of the firstjaw 22 a and tissue captured between the first and second jaws 22 a, 22b, as illustrated in FIGS. 4A-4C. The non-conductive layer 97 can bepositioned, or at least partially positioned, between the conductivelayer 95 and an outer electrically conductive layer 99, as illustratedin FIG. 4A-4C. In certain instances, electrical current can pass betweenthe conductive layer 42 and the outer conductive layer 99 throughtissue, for example. The conducted current can be employed to treat,seal, and/or cut the tissue.

Further to the above, the electrical current may pass between anelectrically conductive layer 95 of the electrode 94 and an electricallyconductive portion 50 a of a protrusion or projection 50 through tissuegripped by the electrically conductive portion 50 a. In certaininstances, the conducted current may also pass between the electricallyconductive portion 50 a and the conductive layer 42 through the tissuegripped, or at least partially gripped, by the electrically conductiveportion 50 a. The reader will appreciate that the conductive nature ofthe electrically conductive portion 50 a facilitates the passing of thecurrent through the tissue gripped, or at least partially gripped, bythe electrically conductive portion 50 a. In certain instances, theconducted current can be employed to treat, seal, and/or cut the tissuegripped by the electrically conductive portion 50 a.

Referring primarily to FIG. 6, the conductive layer 42 can be disposed,or at least partially disposed, over an electrically non-conductivelayer 46. In certain instances, the non-conductive layer 46 may comprisea receiving shell 47. In such instances, the conductive layer 42 can beembedded, or at least partially embedded, in the receiving shell 47, asillustrated in FIG. 4, for example. The receiving shell 47 may include aplurality of receiving portions or sockets 46 a. In at least oneinstance, a protrusion or projection 50 can be fastened (e.g., glued) tothe non-conductive layer 46. In certain instances, as illustrated inFIG. 4A, a protrusion or projection 50 can be partially embedded in areceiving portion 46 a.

The electrically conductive layer 42 may include an outer surface 43facing away from the non-conductive layer 46. The outer surface 43 maycontact tissue captured between the first and second jaws 22 a, 22 b,for example. In certain instances, as illustrated in FIG. 6, thenon-conductive layer 46 may extend between the conductive layer 42 and abase 48. In certain instances, as illustrated in FIG. 4, the base 48 mayinclude an electrically conductive layer 101. In such instances, thenon-conductive layer 46 can be positioned, or at least partiallypositioned, between the conductive layer 42 and the conductive layer101, as illustrated in FIGS. 4A-4C, for example. In certain instances,electrical current can pass between the conductive layer 42 and theconductive layer 101 through tissue, for example. The conducted can beemployed to treat, seal, and/or cut the tissue.

In certain instances, referring to FIGS. 4-4B and 6, the electricallyconductive layer 42 may be comprised of a first lateral portion 42 a anda second lateral portion 42 b. The lateral portions 42 a, 42 b mayextend, or at least partially extend, on opposite lateral sides of theelongate slot 40, for example. In certain instances, as illustrated inFIG. 6, the conductive layer 42 may include a plurality of openings orapertures 44. In various instances, the openings 44 can be arranged inrows that extend in parallel, or at least substantially in parallel,with the elongate slot 40. For example, as illustrated in FIG. 4, afirst row of the openings 44 and a second row of the openings 44 may bedisposed on opposite lateral sides of the slot 40. Furthermore, theprotrusions 50 can be arranged in rows that extend in parallel, or atleast substantially in parallel, with the elongate slot 40. For example,as illustrated in FIG. 4, a first row of the protrusions 50 and a secondrow of the protrusions 50 may be disposed on opposite lateral sides ofthe slot 40. In certain instances, the protrusions 50 can be in anyarray, offset, laterally across from one another, or staggered along alength of one or both of the jaws 22 a, 22 b.

In certain instances, an opening or aperture 44 may define athrough-hole that extends through the conductive layer 42 along an axisthat intersects the conductive layer 42. In certain instances, thethrough-hole can be reamed, drilled, or milled through the conductivelayer 42 along, or at least substantially along, an axis L thatintersects the outer surface 43 of the conductive layer 42, asillustrated in FIG. 4A. In certain instances, the axis L can beperpendicular, or at least substantially perpendicular, to a planeextending along, or at least substantially along, the outer surface 43of the conductive layer 42. In certain instances, the opening 44 maydefine a perimeter wall 44 a. In certain instances, as illustrated inFIG. 6, the perimeter wall 44 a may comprise cylindrical, or at leastsubstantially cylindrical, shape.

In certain instances, as illustrated in FIG. 4C, a barrier 49 mayextend, or at least partially extend, between a perimeter wall 44 a ofthe conductive layer 42 and a corresponding conductive portion 50 a, forexample. The barrier 49 may insulate the perimeter wall 44 a from theconductive portion 50 a. An outer conductive surface 51 may remainexposed. The surface 51 may be configured to contact tissue capturedbetween the jaws 22 a, 22 b, for example. In certain instances, thetissue connecting the electrically conductive surface 51 and theelectrically conductive layer 42 may create a passage for current toflow between the protrusion 50 and the electrically conductive layer 42.In at least one example, the conducted current can be employed to treat,seal, and/or cut the tissue disposed, or at least partially disposed,between the electrically conductive surface 51 and the electricallyconductive layer 42.

FIG. 5 illustrates a perspective view of a second jaw 23 of the endeffector 10 of the surgical instrument 2 of FIG. 1, according to oneembodiment. FIG. 5A illustrates a partial cross-sectional view of thesecond jaw 23 of FIG. 5, according to one embodiment. As illustrated inFIG. 5, the second jaw 23 is similar in many respects to the second jaw22 b (FIG. 4). For example, like the second jaw 22 b, the second jaw 23includes the conductive layer 42, and the protrusions 50. Also, like thejaws 22 a, 22 b, tissue is captured between the jaws 22 a, 23, asillustrated in FIG. 5A. However, unlike the jaw 22 b, the protrusions 50of the jaw 23 extend from an electrically conductive layer 48 a. Incertain instances, as illustrated in FIG. 5A, the base 48 may comprisethe conductive layer 48 a. In one example, the protrusions 50 and theconductive layer 48 a may be formed as a single unit. In anotherexample, the protrusions 50 and the conductive layer 48 a may be formedseparately and assembled by attaching the protrusions 50 to theconductive layer 48. In certain instances, the protrusions 50 and theconductive layer 48 a may be comprised of the same, or similar,conductive materials.

The second jaw 23 comprises an electrically non-conductive support orlayer 46′, which is similar in many respects to the non-conductive layer46. For example, like the non-conductive layer 46, the non-conductivelayer 46′ may be comprised of an electrically non-conductive, orinsulative, material, such as plastic and/or ceramic. As illustrated inFIG. 5A, the non-conductive layer 46′ may extend, or at least partiallyextend, between the conductive layer 48 a and the conductive layer 42.The conductive layer 48 a and the conductive layer 42 can be attached toopposite sides of the non-conductive layer 46′. The non-conductive layer46′ may electrically insulate the conductive layer 42 from theconductive layer 48 a.

In certain instances, as illustrated in FIG. 5A, the non-conductivelayer 46′ may comprise a plurality of apertures or openings 57. Theopenings 57 can be configured to receive the protrusions 50. Asillustrated in FIG. 5A, an opening 57 can be aligned, or at leastpartially aligned, with an opening 44 of the conductive layer 42 topermit a protrusion or projection 50 to extend through the opening 57and the opening 44 away from the conductive layer 48 a. In certaininstances, unlike the openings 44, the openings 57 can be tightly fittedaround the protrusions 50. An opening 57 may define a smaller perimeterwall 57 a around a protrusion or projection 50 than the perimeter 44 adefined by the opening 44 around the protrusion 50. In at least oneexample, an opening 57 and an opening 44 can be concentrically alignedabout a longitudinal axis L defined by a protrusion or projection 50, asillustrated in FIG. 5A. In at least one example, a protrusion 50 may bein contact (not shown) with a perimeter wall 57 a of an opening 57surrounding the protrusion 50.

Referring again to FIG. 5A, in certain instances, electrical energy canbe passed from the conductive layer 42 to the conductive portions 50,the conductive layer 95, and/or the conductive layer 99, for example.The tissue gripped, or at least partially gripped, by the conductiveportions 50 can act as a conduit for the electrical current passedbetween the conductive layer 42 and the conductive portions 50. Tissuecan also act as a conduit for the electrical current passed between theconductive layer 42 and the conductive layers 95 and/or 99, for example.In any event, the conducted current can be employed to treat, seal,and/or cut the tissue.

Referring again to FIG. 5A, in certain instances, electrical energy canbe passed from the conductive layer 95 to the conductive portions 50,the conductive layer 42, and/or the conductive layer 99, for example.The tissue gripped, or at least partially gripped, by the conductiveportions 50 can act as a conduit for the electrical current passedbetween the conductive layer 95 and the conductive portions 50. Tissuecan also act as a conduit for the electrical current passed between theconductive layer 95 and the conductive layers 42 and/or 99, for example.In any event, the conducted current can be employed to treat, seal,and/or cut the tissue.

FIG. 7 illustrates a side elevational view of a second jaw 25 of thesurgical instrument 2 of FIG. 1, according to one embodiment, and FIG.7A illustrates a partial cross-sectional view of the second jaw 25 ofFIG. 7, according to one embodiment. As illustrated in FIG. 7, thesecond jaw 25 is similar in many respects to the second jaw 22 b (FIG.4) and/or the second jaw 23 (FIG. 5). For example, like the second jaws22 b, 23, the second jaw 25 includes the conductive layer 42, and theprotrusions 50. Also, like the jaws 22 a, 22 b and the jaws 22 a, 23,tissue is captured between the jaws 22 a, 25.

Referring now to FIGS. 4-7A, one or more of the protrusions 50 mayextend from the non-conductive layer 46, as illustrated in FIG. 4A, orthrough the non-conductive layer 46′, as illustrated in FIG. 5A, towardthe electrically conductive layer 42. In certain instances, a protrusionor projection 50 may extend through an opening 44 of the electricallyconductive layer 42. In certain instances, the protrusion 50 mayprotrude through the outer surface 43 of the electrically conductivelayer 42, as illustrated in FIG. 7. In certain instances, one or moreelectrically conductive portions 50 a may protrude through the outersurface 43 of the electrically conductive layer 42, as illustrated inFIG. 7A.

Referring to FIG. 7A, an electrically conductive portion 50 a mayprotrude or extend a predetermined distance (d1) beyond the outersurface 43 of the outer layer 42. The electrically conductive portion 50a may prevent direct contact between the electrode 94 and theelectrically conductive layer 42 of the electrode 92. In certaininstances, the electrically conductive portion 50 a may maintain aminimum gap between the electrode 94 and the electrically conductivelayer 42 of the electrode 92. In certain instances, the minimum gap canbe defined by the predetermined distance (d1). In certain instances, thepredetermined distance (d1) can be any distance selected from a range ofabout 0.001 inch to about 0.010 inch. In certain instances, thepredetermined distance (d1) can be any distance selected from a range ofabout 0.003 inch to about 0.008 inch. In certain instances, thepredetermined distance (d1) can be about 0.004 inch, for example. Incertain instances, the predetermined distance (d1) can be about 0.005inch, for example.

Referring now primarily to FIG. 7A, a protrusion or projection 50extending through an opening or aperture 44 of the electricallyconductive layer 42 may be spaced apart from the perimeter wall 44 a ofthe opening 44 to prevent, or at least reduce, electrical arcing betweenthe protrusion 50 and the electrically conductive layer 42. In certaininstances, as illustrated in FIG. 7A, the perimeter wall 44 a of theopening 44 may be disposed around, or at least partially around, theprotrusion 50, wherein a predetermined distance (d2) is maintainedbetween the protrusion 50, or at least the electrically conductiveportion 50 a of the protrusion 50, and the wall 44 a of the opening 44.

Although the electrically conductive portion 50 a is spaced apart fromthe perimeter wall 44 a, current may still be conducted between theelectrically conductive portion 50 a and the electrically conductivelayer 42 through tissue disposed therebetween, as illustrated in FIG.7A. In such instances, the conducted current may be employed to treat,seal, and/or cut the tissue disposed, or at least partially disposed,between the electrically conductive portion 50 a and the electricallyconductive layer 42, for example.

In certain instances, the predetermined distance (d2) can be anydistance selected from a range of about 0.001 inch to about 0.010 inch.In certain instances, the predetermined distance (d2) can be anydistance selected from a range of about 0.003 inch to about 0.008 inch.In certain instances, the predetermined distance (d2) can be about 0.004inch, for example. In certain instances, the predetermined distance (d2)can be about 0.005 inch, for example.

FIG. 8 illustrates a perspective view of a second jaw 27 of the endeffector 10 of the surgical instrument 2 of FIG. 1, according to oneembodiment. FIG. 9 illustrates a partial cross-sectional view of thesecond jaw 27 of FIG. 8, according to one embodiment. As illustrated inFIG. 8, the second jaw 27 is similar in many respects to the second jaw23 (FIG. 5). For example, like the second jaw 23, the second jaw 27includes the conductive layer 42, the conductive layer 48 a, thenon-conductive layer 46′, and the protrusions 50. Also, like the secondjaw 23, the protrusions 50 of the second jaw 27 may extend from theconductive layer 48 a through the non-conductive layer 46′, for example.Also, like the jaws 22 a, 23, tissue is captured between the jaws 22 a,25, as illustrated in FIG. 9.

Referring to FIGS. 8-10, a protrusion or projection 50 of the second jaw27 may extend from the conductive layer 48 a and can be partiallysurrounded by an electrically non-conductive barrier 49 extending fromthe non-conductive layer 46′. In certain instances, as illustrated inFIG. 8, the barrier 49 can be disposed, or at least partially disposed,between a protrusion or projection 50 and the electrically conductivelayer 42 to prevent, or at least reduce, electrical arcing between theprotrusion 50 and the electrically conductive layer 42. An electricallyconductive surface 51 of the protrusion 50 may remain exposed to permitcurrent to flow between the protrusion 50 and the electricallyconductive layer 42 through tissue disposed, or at least partiallydisposed, therebetween, for example. In certain instances, the tissueconnecting the electrically conductive surface 51 and the electricallyconductive layer 42 may create a passage for current to flow between theprotrusion 50 and the electrically conductive layer 42. In at least oneexample, the conducted current can be employed to treat, seal, and/orcut the tissue disposed, or at least partially dispose, between theelectrically conductive surface 51 and the electrically conductive layer42.

In certain instances, referring primarily to FIG. 10, a protrusion orprojection 50 of the second jaw 27 may be partially enclosed within thebarrier 49 of the non-conductive layer 46′. In various instances, theprotrusion 50 may comprise a semi-cylindrical shape comprising a firstbase 53 and a second base 55, as illustrated in FIG. 10, for example.The barrier 49 may comprise crescent shape configured to separate, or atleast partially separate, an arcuate portion of the semi-cylindricalprotrusion 50 from the electrically conductive layer 42 to prevent, orat least reduce, electrical arcing between the semi-cylindricalprotrusion 50 and the electrically conductive layer 42. The second base55 may extend, or at least partially extend in a first plane which isperpendicular, or substantially perpendicular, to a second plane definedby the first base 53, for example. In certain instances, the first base53 can be flush with an outer surface 49 a of the barrier 49, forexample.

In certain instances, the first base 53 and/or the second base 55 areexposed, as illustrated in FIG. 10. Said another way, the first base 53and/or the second base 55 may not be enclosed by the non-conductivelayer 46′. Yet said another way, the first base 53 and/or the secondbase 55 can contact tissue captured between the first jaw 22 a and thesecond jaw 27. In such instances, the captured tissue may create apassage for current to flow between the electrically conductive layer 42and the first base 53 and/or the second base 55. In at least oneexample, the conducted current can be employed to treat, seal, and/orcut the tissue connecting the electrically conductive layer 42 and thefirst base 53 and/or the second base 55.

One or more of the switches described herein may comprise mechanicalswitches, electro-mechanical switches, and/or solid state switches. Incertain instances, one or more of the switches of the present disclosuremay comprise open, inactive, and/or non-conductive positions, states,and/or configurations. In certain instances, one or more of the switchesof the present disclosure may comprise closed, active, and/or conductivepositions, states and/or configurations. In certain instances, one ormore of the switches of the present disclosure can be transitioned fromthe open, inactive, and/or non-conductive positions, states, and/orconfigurations to the closed, active, and/or conductive positions,states and/or configurations to close and/or activate one or morecircuits associated with such switches, for example.

The devices disclosed herein can be designed to be disposed of after asingle use, or they can be designed to be used multiple times. In eithercase, however, the device can be reconditioned for reuse after at leastone use. Reconditioning can include any combination of the steps ofdisassembly of the device, followed by cleaning or replacement ofparticular pieces, and subsequent reassembly. In particular, the devicecan be disassembled, and any number of the particular pieces or parts ofthe device can be selectively replaced or removed in any combination.Upon cleaning and/or replacement of particular parts, the device can bereassembled for subsequent use either at a reconditioning facility, orby a surgical team immediately prior to a surgical procedure. Thoseskilled in the art will appreciate that reconditioning of a device canutilize a variety of techniques for disassembly, cleaning/replacement,and reassembly. Use of such techniques, and the resulting reconditioneddevice, are all within the scope of the present application.

Preferably, the disclosure described herein will be processed beforesurgery. First, a new or used instrument is obtained and if necessarycleaned. The instrument can then be sterilized. In one sterilizationtechnique, the instrument is placed in a closed and sealed container,such as a plastic or TYVEK bag. The container and instrument are thenplaced in a field of radiation that can penetrate the container, such asgamma radiation, x-rays, or high-energy electrons. The radiation killsbacteria on the instrument and in the container. The sterilizedinstrument can then be stored in the sterile container. The sealedcontainer keeps the instrument sterile until it is opened in the medicalfacility.

Any patent, publication, or other disclosure material, in whole or inpart, that is the to be incorporated by reference herein is incorporatedherein only to the extent that the incorporated materials does notconflict with existing definitions, statements, or other disclosurematerial set forth in this disclosure. As such, and to the extentnecessary, the disclosure as explicitly set forth herein supersedes anyconflicting material incorporated herein by reference. Any material, orportion thereof, that is the to be incorporated by reference herein, butwhich conflicts with existing definitions, statements, or otherdisclosure material set forth herein will only be incorporated to theextent that no conflict arises between that incorporated material andthe existing disclosure material.

While this disclosure has been described as having example designs, thepresent disclosure may be further modified within the spirit and scopeof the disclosure. This application is therefore intended to cover anyvariations, uses, or adaptations of the disclosure using its generalprinciples. Further, this application is intended to cover suchdepartures from the present disclosure as come within known or customarypractice in the art to which this disclosure pertains.

The entire disclosures of:

U.S. patent application Ser. No. 12/576,789, entitled SURGICALINSTRUMENT FOR TRANSMITTING ENERGY TO TISSUE COMPRISING NON-CONDUCTIVEGRASPING PORTIONS, filed Oct. 9, 2009;

U.S. patent application Ser. No. 14/075,839, entitled ELECTROSURGICALDEVICES, filed Nov. 8, 2013;

U.S. patent application Ser. No. 14/075,863, entitled ELECTROSURGICALDEVICES, filed Nov. 8, 2013; and

U.S. patent application Ser. No. 14/229,033, entitled DISTAL SEALING ENDEFFECTOR WITH SPACERS, filed Mar. 28, 2014, are hereby incorporated byreference herein.

What is claimed is:
 1. A surgical instrument, comprising: an endeffector, comprising: a first jaw comprising a first electricallyconductive layer; and a second jaw, wherein at least one of the firstjaw and the second jaw is movable relative to the other one of the firstjaw and the second jaw to transition the end effector between a firstconfiguration and a second configuration, the second jaw comprising: asecond electrically conductive layer defining a first plurality ofopenings arranged at a plurality of locations on the second electricallyconductive layer; an electrically non-conductive layer comprising asecond plurality of openings, wherein the first electrically conductivelayer and the electrically non-conductive layer are configured to be onopposite sides of the second electrically conductive layer; and a thirdelectrically conductive layer comprising a plurality of electricallyconductive members extending from the third electrically conductivelayer and projecting through the second plurality of openings and thefirst plurality of openings to maintain a predetermined gap between thefirst electrically conductive layer and the second electricallyconductive layer, wherein the second electrically conductive layer andthe third electrically conductive layer are on opposite sides of theelectrically non-conductive layer; and wherein the second electricallyconductive layer is configured to conduct electrical energy to the firstelectrically conductive layer and the plurality of electricallyconductive members through tissue disposed between the first jaw and thesecond jaw to treat the tissue.
 2. The surgical instrument of claim 1,wherein the first and second plurality of openings are located at apredetermined distance from the plurality of electrically conductivemembers.
 3. The surgical instrument of claim 2, wherein thepredetermined gap is equal to or greater than the predetermineddistance.
 4. The surgical instrument of claim 2, wherein thepredetermined distance is any distance selected from a range of about0.001 inch to about 0.010 inch.
 5. The surgical instrument of claim 2,wherein the predetermined distance is about 0.004 inch.
 6. The surgicalinstrument of claim 1, wherein each of the plurality of electricallyconductive members extend along an axis that passes through theelectrically non-conductive layer.
 7. The surgical instrument of claim6, wherein each of the first and second plurality of openings define awall that at least partially extends about the axis.
 8. The surgicalinstrument of claim 7, further comprising a plurality of electricallynon-conductive barriers configured to separate corresponding walls ofthe first and second plurality of openings from the plurality ofelectrically conductive members.
 9. The surgical instrument of claim 1,wherein the predetermined gap between the first electrically conductivelayer and the second electrically conductive layer is any gap selectedfrom a range of about 0.001 inch to about 0.010 inch.
 10. The surgicalinstrument of claim 1, wherein the predetermined gap between the firstelectrically conductive layer and the second electrically conductivelayer is about 0.004 inch.
 11. The surgical instrument of claim 1,wherein the electrically non-conductive layer comprises a plurality ofsockets configured to partially receive the plurality of electricallyconductive members.
 12. The surgical instrument of claim 1, wherein theplurality of electrically conductive members are attached to theelectrically non-conductive layer.
 13. The surgical instrument of claim1, wherein the plurality of electrically conductive members are arrangedin a first row and a second row.
 14. The surgical instrument of claim13, further comprising a longitudinal slot extending longitudinallybetween the first row and the second row.
 15. An end effector for asurgical instrument, the end effector comprising: a first jaw comprisinga first electrically conductive layer; and a second jaw comprising: asecond electrically conductive layer comprising a plurality ofelectrically conductive projections extending from the secondelectrically conductive layer, wherein at least one of the firstelectrically conductive layer and the plurality of electricallyconductive projections is movable relative to the other one of the firstelectrically conductive layer and the plurality of electricallyconductive projections to capture tissue therebetween, and wherein theplurality of electrically conductive projections are integral with thesecond electrically conductive layer; a first electricallynon-conductive support comprising a first plurality of aperturesarranged at a plurality of locations on the first electricallynon-conductive support, wherein the plurality of electrically conductiveprojections extend through the first plurality of apertures; and a thirdelectrically conductive layer comprising a second plurality ofapertures, wherein the plurality of electrically conductive projectionsextend through the second plurality of apertures, and wherein the firstelectrically non-conductive support is positioned between the secondelectrically conductive layer and the third electrically conductivelayer.
 16. The end effector of claim 15, wherein the second plurality ofapertures are larger than the first plurality of apertures.
 17. The endeffector of claim 15, wherein each of the second plurality of aperturesdefine a wall, and wherein each wall is separated from a correspondingelectrically conductive projection of the plurality of electricallyconductive projections by a predetermined gap.
 18. The end effector ofclaim 15, further comprising a second electrically non-conductivesupport, wherein the first electrically non-conductive support and thesecond electrically non-conductive support are positioned on oppositesides of the captured tissue.
 19. The end effector of claim 18, furthercomprising a fourth electrically conductive layer, wherein the secondelectrically non-conductive support is positioned between the fourthelectrically conductive layer and the first electrically conductivelayer.
 20. The end effector of claim 15, wherein each of the theplurality of electrically conductive projections define an axis thatpasses through the first plurality of apertures and the second pluralityof apertures.
 21. The end effector of claim 15, wherein the thirdelectrically conductive layer is configured to conduct electrical energyto the first electrically conductive layer and at least one of theplurality of electrically conductive projections through tissue disposedbetween the first jaw and the second jaw to treat the tissue.
 22. Theend effector of claim 15, wherein the third electrically conductivelayer comprises an inner perimeter defining a longitudinal slotextending along a length of the second jaw, and wherein the innerperimeter comprises cutouts defining the second plurality of apertures.23. A surgical end effector, comprising: a first jaw comprising a firstelectrically conductive layer; and a second jaw, wherein at least one ofthe first jaw and the second jaw is movable relative to the other one ofthe first jaw and the second jaw to transition the surgical end effectorbetween a first configuration and a second configuration, the second jawcomprising: a second electrically conductive layer comprising aplurality of electrically conductive projections extending from thesecond electrically conductive layer; a first electricallynon-conductive support comprising first apertures arranged at locationson the first electrically non-conductive support, wherein the pluralityof electrically conductive projections extend through the firstapertures; and a third electrically conductive layer comprising an innerperimeter defining a longitudinal slot extending along a length of thesecond jaw, wherein the third electrically conductive layer comprisesside cavities defined in the inner perimeter, and wherein theelectrically conductive projections extend through the side cavities,and wherein the first electrically non-conductive support is positionedbetween the second electrically conductive layer and the thirdelectrically conductive layer on the second jaw.